FALK Ultramite UB Installation and operating instructions
How to Use This Manual
This manual provides detailed instructions on installation and
maintenance of gear drives and couplings. Use the table of
contents below to locate required information.
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE
FREE SERVICE.
Table of Contents
Drive Assembly Instructions .................. Page2
Fastener Tightening Torques ................. Page5
Shaft Connections ........................ Page5
Retaining Methods for Shaft Mounted Drives ..... Page6
Installation &Removal of TATaper Bushing ........Page6
Installation &Removal of Shrink Discs..........Pages 7-8
Lubrication Recommendations ............... Page8
Extreme Pressure (EP) Lubricants .............. Page8
Oil Levels ............................. Page10
Mounting Positions ....................... Page10
Lubricant Changes ....................... Page11
Preventive Maintenance ................... Page11
Bearing Greases ........................ Page11
Stored and Inactive Gear Drives ............. Page12
Introduction
Credit for long service and dependable operation of a gear
drive is often given to the engineers who designed it, or the
craftsmen who constructed it, or the sales engineer who
recommended the type and size. Ultimate credit belongs to the
mechanic on the job who worked to make the foundation rigid
and level, who accurately aligned the shafts and carefully
installed the accessories, and who made sure that the drive
received lubrication at prescribed intervals. The details of this
important job are the subject of this manual.
NAMEPLATE — Operate Falk gear drives only at horsepower,
speed and ratio shown on nameplate and in the mounting
position for which it was ordered. Before changing any one of
these, submit complete nameplate data and new application
conditions to the Factory for correct oil level, parts and
application approval.
WARNING:Consult applicable local and national safety
codes for proper guarding of rotating members. Lock out
power source and remove all external loads from drive before
servicing drive or accessories.
Warranty
The Falk Corporation (the “Company") warrants that, for a
period of one year from the date of shipment, the product
described herein will deliver successfully its rated output as
indicated on the nameplate, provided, it is properly installed
and maintained, correctly lubricated, and operated in the
environment and within the limits of speed, torque or other
load conditions for which it was sold. Such product is expressly
not warranted against failure or unsatisfactory operation
resulting from dynamic vibrations imposed upon it by the drive
system in which it is installed unless the nature of such
vibrations has been fully defined and expressly accepted in
writing by the Company as a condition of operation.
General Information
The following instructions apply to standard Falk Type UB drives
shown above. If a drive is furnished with special features, refer to
the supplementary instructions shipped with the drive.
WELDING — Do not weld on the gear drive or accessories
without prior approval from The Falk Corporation. Welding on
the drive may cause distortion of the housing or damage to
the bearings and gear teeth. Welding without prior approval
could void the warranty.
EFFECTS OF SOLAR ENERGY — If the gear drive operates in
the sun at ambient temperatures over 100°F (38°C), then special
measures should be taken to protect the drive from solar energy.
This protection can consist of a canopy over the drive or reflective
paint on the drive. If neither is possible, refer to Falk.
FOUNDATION GENERAL —To facilitate oil drainage, elevate
the gear drive foundation above the surrounding floor level. If
desired, replace the drive oil drain plug with a valve, but provide a
guard to protect the valve from accidental opening or breakage.
FOUNDATION, STEEL — When mounting gear drive on
structural steel, it is recommended that an engineered design be
utilized for a pedestal, adapter base or bed to provide sufficient
rigidity, to prevent induced loads from distorting the housing and
causing gear misalignment. In the absence of an engineered
design, it is recommended that a base plate, with thickness equal
to or greater than the thickness of the drive feet, be securely
bolted to steel supports and extend under the entire drive.
FOUNDATION, CONCRETE — If a concrete foundation is
used, allow the concrete to set firmly before bolting down the
gear drive. For the best type of mounting, grout structural steel
mounting pads into the mounting base, as illustrated, rather
than grouting the drive directly into the concrete.
Motors and other
components mounted on
motor plates may become
misaligned during shipment.
ALWAYS check alignment
after installation.
GEAR DRIVE ALIGNMENT — Align drive with driven
equipment by placing broad, flat shims under all mounting pads.
Start at the low speed shaft end and level across the length and
then the width of the drive. Check with a feeler gauge to make
certain that all pads are supported to prevent distortion of
housing when drive is bolted down. After drive is aligned with
driven equipment and bolted down, align prime mover to drive
input shaft. Refer to Pages 5and 6for coupling alignment.
Check high speed shaft coupling alignment. If the coupling is
misaligned, the drive is shimmed incorrectly. Re-shim drive and
recheck high speed coupling alignment. If necessary, realign
motor.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 November 2002
®
Ultramite ®•Installation & Maintenance Instructions
Type UB •Sizes 03 thru 12 (Page 1 of 12)
TYPE UB
Drive Assembly Instructions
Refer to Table 1 to determine the appropriate assembly
procedure (G,G&RorG&H)forthetype of drive/motor
combination being assembled. Then refer to the appropriate
assembly procedure.
SUMMARY OF MOTOR ADAPTER FITTING SEQUENCES
G — Fit motor adapter to basic housing and then attach motor.
G&R—Attach motor adapter to basic housing, then fit
adapter ring to motor before attaching motor to assembly.
G&H—Attach motor adapter to basic housing, then fit
adapter extension to motor before attaching motor to
assembly.
PROCEDURE G —Figure 1
Important — The high speed motor adapters for drives
requiring assembly procedure G will initially be assembled
and sealed with Loctite at the Factory, unless otherwise
specified. During assembly, Do Not break Loctite Seal.
1. Place basic housing on a workbench so that high speed
end is facing up as illustrated in Figure 1. If necessary,
block housing so that it is stable and level.
2. Remove high speed motor adapter from basic housing
ONLY if replacing.
3. Clean mating surfaces of basic housing, high speed
motor adapter, and electric motor (use Loctite 7070
Super Clean or equivalent). Check for and remove any
burrs from mating surfaces.
4. Fill basic housing with quantity of oil specified in Table 9,
Page 8—Approximate Oil Quantities.
5. Apply Anti-fretting compound (Dow Corning G-n or
equivalent) to bore of high speed motor adapter.
6. Depending upon motor shaft diameter, either a plastic
key or motor bushing will be furnished. Refer to the
appropriate instructions following:
Plastic Key — If installed, remove the metal key from the
motor shaft; this key will not be used.
For motor shafts with a closed ended full depth keyway
(IEC motors), shorten plastic key to fit keyway. Note:
plastic key should be the same length as the metal key
just removed.
Motor Bushing — Install motor bushing into bore of high
speed motor adapter. Fit metal key into keyway of motor
shaft. This will assemble into the motor bushing and drive
through it. Apply Anti-fretting compound (Dow Corning
G-n or equivalent) to motor shaft.
7. Apply liquid gasket material (Loctite® 518, Falk Part #
2918376) furnished to flange face of basic housing as
illustrated in Figure 3, Page 4.Caution: This step must
be followed to prevent leakage.
8. Align mounting holes of high speed motor adapter with
threaded holes of basic housing while assembling motor
adapter to basic housing. Secure high speed motor
adapter to basic housing using fasteners with copper
washers (when provided). Torque fasteners to value
specified in Table 4, Page5—Tightening Torques.
9. Determine appropriate position that motor conduit box
must be in once motor is assembled to basic housing.
Refer to Figure 4, Page 4.Slide motor shaft into high
speed motor adapter, aligning key of shaft with keyway in
motor adapter bore.
10. Align threaded mounting holes of high speed motor
adapter with holes of electric motor. Secure motor to
basic housing using fasteners with copper washers (when
provided). Torque fasteners to the value specified in Table
4,Page5—Tightening Torques.
PROCEDUREG&H—Figure 2
Important — The high speed motor adapters for drives
requiring assembly procedureG&Hwill initially be assembled
and sealed with Loctite at the Factory, unless otherwise
specified. During assembly, Do Not break Loctite Seal.
1. Place basic housing on a workbench so that high speed
end is facing up as illustrated in Figure 2.If necessary,
block housing so that it is stable and level.
2. Remove high speed motor adapter from basic housing
ONLY if replacing.
3. Clean mating surfaces of basic housing, high speed
®
The Falk Corporation, P.O. Box 492, Zip 53201-0492288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131November 2002
Installation & Maintenance Instructions •Ultramite ®
(Page 2 of 12) Sizes 03 thru 12 •Type UB
BASIC
HOUSING
FASTENERS
ELECTRIC
MOTOR
HIGH SPEED
MOTOR ADAPTER
PLASTIC KEY
(IF PROVIDED)
MOTOR BUSHING
(IF PROVIDED)
FASTENERS
FIGURE 1
Table 1 — Motor Adapter Fitting Prodecures
NEMA MOTORS
PROCEDURE G,G & R, ORG&HAREUSED FOR ALL DRIVE SIZES
motor adapter, and electric motor (use Loctite 7070
Super Clean or equivalent). Check for and remove any
burrs from mating surfaces.
4. Fill basic housing with quantity of oil specified in Table 9,
Page 8—Approximate Oil Quantities.
5. Apply Anti-fretting compound (Dow Corning G-n or
equivalent) to bore of high speed motor adapter.
6. Depending upon motor shaft diameter, either a plastic
key or motor bushing will be furnished. Refer to the
appropriate instructions following:
Plastic Key — If installed, remove the metal key from the
motor shaft; this key will not be used.
For motor shafts with a closed ended full depth keyway (IEC
motors), shorten plastic key to fit keyway. Note: plastic key
should be the same length as the metal key just removed.
Motor Bushing — Install motor bushing into bore of high
speed motor adapter. Fit metal key into keyway of motor
shaft. This will assemble into the motor bushing and drive
through it. Apply Anti-fretting compound (Dow Corning
G-n or equivalent) to motor shaft.
7. Apply liquid gasket material (Loctite® 518, Falk Part #
2918376) furnished to flange face of basic housing as
illustrated in Figure 3, Page 4. Caution: This step must
be followed to prevent leakage.
8. Align mounting holes of high speed motor adapter with
threaded holes of basic housing while assembling motor
adapter to basic housing. Secure high speed motor
adapter to basic housing using fasteners with copper
washers (when provided). Torque fasteners to value
specified in Table 4, Page5—Tightening Torques.
9. Install studs provided into motor flange face.
10. Attach adapter extension to motor, aligning holes in
adapter extension with studs mounted in motor.
11. Determine appropriate position that motor conduit box
must be in once motor is assembled to basic housing.
Refer to Figure 4, Page 4.Slide motor shaft into high
speed motor adapter, aligning key of shaft with keyway in
motor adapter bore.
12. Align mounting holes of high speed motor adapter with
studs of motor. Secure motor to the basic housing
assembly using fasteners with copper washers (when
provided). Torque fasteners to the value specified in Table
4,Page5—Tightening Torques.
PROCEDUREG&R—Figure 2
Important — The high speed motor adapters for drives
requiring assembly procedureG&Rwillinitially be assembled
and sealed with Loctite at the Factory, unless otherwise
specified. During assembly, Do Not break Loctite Seal.
1. Place basic housing on a workbench so that high speed
end is facing up as illustrated in Figure 2. If necessary,
block housing so that it is stable and level.
2. Remove high speed motor adapter from basic housing
ONLY if replacing.
3. Clean mating surfaces of basic housing, high speed
motor adapter, and electric motor (use Loctite 7070
Super Clean or equivalent). Check for and remove any
burrs from mating surfaces.
4. Fill basic housing with quantity of oil specified in Table 9,
Page 8—Approximate Oil Quantities.
5. Apply Anti-fretting compound (Dow Corning G-n or
equivalent) to bore of high speed motor adapter.
6. Depending upon motor shaft diameter, either a plastic
key or motor bushing will be furnished. Refer to the
appropriate instructions following:
Plastic Key — If installed, remove the metal key from the
motor shaft; this key will not be used.
For motor shafts with a closed ended full depth keyway
(IEC motors), shorten plastic key to fit keyway. Note:
plastic key should be the same length as the metal key
just removed.
Motor Bushing — Install motor bushing into bore of high
speed motor adapter. Fit metal key into keyway of motor
shaft. This will assemble into the motor bushing and drive
through it. Apply Anti-fretting compound (Dow Corning
G-n or equivalent) to motor shaft.
7. Apply liquid gasket material (Loctite® 518, Falk Part #
2918376) furnished to flange face of basic housing as
illustrated in Figure 3, Page 4.Caution: This step must
be followed to prevent leakage.
8. Align mounting holes of high speed motor adapter with
threaded holes of basic housing while assembling motor
adapter to basic housing. Secure high speed motor
adapter to basic housing using fasteners with copper
washers (when provided). Torque fasteners to value
specified in Table 4, Page5—Tightening Torques.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 November 2002
®
Ultramite ®•Installation & Maintenance Instructions
Type UB •Sizes 03 thru 12 (Page 3 of 12)
BASIC
HOUSING
FASTENERS
ELECTRIC
MOTOR
ADAPTER
EXTENSION/RING
PLASTIC KEY
(IF PROVIDED)
MOTOR BUSHING
(IF PROVIDED)
FASTENERS
HIGH SPEED
MOTOR ADAPTER
MOTOR STUDS
FIGURE 2
9. Install studs provided into motor flange face.
10. Attach adapter ring to motor, aligning holes in adapter
ring with studs mounted in motor.
11. Determine appropriate position that motor conduit box
must be in once motor is assembled to basic housing.
Refer to Figure 4 below. Slide motor shaft into high speed
motor adapter, aligning key of shaft with keyway in motor
adapter bore.
12. Align mounting holes of high speed motor adapter with
studs of motor. Secure motor to the basic housing
assembly using fasteners with copper washers (when
provided). Torque fasteners to the value specified in Table
4,Page5—Tightening Torques.
ASSEMBLE OUTPUT FLANGE TO DRIVE
1. Place drive on a workbench so that the side to which the
output flange will be installed is facing up. If necessary,
block drive so that it is stable and level.
2. Clean mating surfaces of drive and output flange
thoroughly using Loctite 7070 Super Clean or equivalent.
Check for and remove any burrs from mating surfaces.
3. Assemble output flange to drive (see Figure 5)and secure
using the fasteners furnished. Torque fasteners to the
value shown in Table 4, Page5—Tightening Torques.
ASSEMBLE TORQUE ARM BRACKET TO DRIVE
1. Place drive on a workbench so that the side in which the
torque arm bracket will be installed is easily accessible. If
necessary, block drive so that it is stable and level.
2. Clean mating surfaces of drive and torque arm bracket
thoroughly using Loctite 7070 Super Clean or equivalent.
Check for and remove any burrs from mating surfaces.
3. Assemble torque arm bracket to drive in the required
position (see Figure 6) and secure using the fasteners
furnished. Torque fasteners to the value shown in Table 4,
Page5—Tightening Torques.
The support to which the torque arm is to be fastened must
sustain the torque reaction listed in Table2—Torque Arm
Load Reaction. Use SAE grade 5 minimum fasteners for
anchoring torque arm to support structure; refer to Table 3 —
Torque Arm Anchoring Fasteners, for recommended fastener
diameter. Fastener length is dependent on support structure.
Bolt the torque arm to supporting structure and tighten bolt
(provided by others) until it is seated against brackets. Do not
bend the support clevis bracket. Clearance between the clevis
bracket and torque arm is required.
®
The Falk Corporation, P.O. Box 492, Zip 53201-0492288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131November 2002
Installation & Maintenance Instructions •Ultramite ®
(Page 4 of 12) Sizes 03 thru 12 •Type UB
DRIVE HOUSING BASE FLANGE
FIGURE 5
TORQUE ARM
BRACKET
FIGURE 6
TABLE 2 — Torque Arm Load Reaction (lb) H
DRIVE SIZE Maximum Load (lb)
03UB 715
04UB 1215
05UB 1515
06UB 1810
07UB 2910
08UB 3985
09UB 5430
10UB 7160
12UB 10,010
HBased on worst case loading conditions, consult Falk for loads based on
specific application data.
C (180 )
oA(0)
o
B(90)
o
D (270 )
o
VIEW FACING L.S. END
FIGURE 4
IMPORTANT: CIRCLE EACH FASTENER
HOLE WITH A CONTINUOUS AND
UNBROKEN BEAD OF LOCTITE 518
OR EQUIVALENT. THEN CONNECT
EACH ADJACENT FASTENER HOLE
WITH A CONTINUOUS AND UNBROKEN
BEAD OF LOCTITE 518 OR EQUIVALENT.
FIGURE 3
TABLE 3 — Torque Arm Anchoring Fasteners
DRIVE SIZE Metric Fastener †Inch Fastener †
03UB M10 .375-16 UNC
04UB M10 .375-16 UNC
05UB M16 .625-11 UNC
06UB M16 .625-11 UNC
07UB M24 .875-9 UNC
08UB M24 .875-9 UNC
09UB M24 .875-9 UNC
10UB M24 .875-9 UNC
12UB M36 1.375-6 UNC
†Standard fastener sizes are given. Use of a fitted pin is recommended.
INSTALL SOLID OUTPUT SHAFT
1. Place drive on a workbench so that the hollow shaft is
horizontal. If necessary, block drive so that it is stable and
level.
2. Clean surfaces of hollow shaft and solid output shaft
thoroughly using Loctite 7070 Super Clean or equivalent.
Check for and remove any burrs from mating surfaces.
3. Install key into keyway of solid output shaft. Apply
Anti-fretting compound (Dow Corning G-n or equivalent)
to bore of low speed shaft.
4. Slide solid output shaft into bore of low speed shaft,
aligning key with keyway in bore of low speed shaft.
Note: For single extension solid output shaft (viewing from
low speed end of drive), confirm right or left hand
extension. Refer to Figure 7.
5. Install retaining ring into groove of solid output shaft.
Install end cover (single ended solid output shaft
applications only).
6. Install extension key into extension keyway in solid output
shaft.
Fastener Tightening Torques
Use the tightening torque values specified in Table 4, for
fastening Falk gear drives, motors, and accessories to their
mounting surfaces with non-lubricated fasteners. DO NOT use
these values for “torque locking" fasteners or for fastening
components with aluminum feet or with soft gaskets or
vibration dampers on the mounting surface. If the tightening
torque exceeds the capacity of the torque wrench, use a
torque multiplier. Use Grade 5 fasteners for diameters through
1.50".
For assembling motors, high speed adapters, output flanges
or torque arm brackets to drives, refer to the tightening torque
values listed in Table 4 for metric fasteners. Use ISO grade
8.8 minimum fasteners for securing output flanges and/or
torque arms to drives.
Shaft Connections
WARNING:Provide suitable guards in accordance with
OSHA standards.
Input and output shaft extension diameter tolerance is
+.0000" to –.0005" for shafts up to 1.750" diameter and
+.0000" to –.0010" for shafts larger than 1.750" diameter.
The fitted component must be machined to ensure proper fit.
DO NOT drive coupling hub, pinion, sprocket or pulley on the
shaft. An endwise blow on the shaft may damage gears and
bearings. Coupling hubs, pinions, sprockets or pulleys must be
installed onto the shaft using a screw jack device fitted into the
threaded hole provided in the end of the shaft; refer to Table 5.
COUPLING CONNECTIONS — The performance and life
of any coupling depends largely upon how well the coupling is
installed and serviced. Refer to the coupling manufacturer’s
manual for specific instructions.
CORRECT METHOD
Heat interference fitted
coupling hubs, pinions,
sprockets or pulleys to a
maximum of 212°F (100°C)
and slide onto gear drive shaft.
INCORRECT METHOD
DO NOT drive coupling hub,
pinion, sprocket or pulley onto
the shaft. An endwise blow on
the shaft/coupling may damage
gears and bearings.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 November 2002
®
Ultramite ®•Installation & Maintenance Instructions
Type UB •Sizes 03 thru 12 (Page 5 of 12)
KEY
SOLID
OUTPUT
SHAFT
RETAINING
RING
END
COVER
SINGLE ENDED
SOLID OUTPUT SHAFT
RETAINING
RING
SOLID
OUTPUT
SHAFT
DOUBLE ENDED
SOLID OUTPUT SHAFT
LEFT
HAND
RIGHT
HAND
VIEW FACING L.S. END
FIGURE 7
Metric
Fasteners
Output Flange, Feet and
Torque Arm Bracket
Electric Motor and
High Speed Motor Adapter
M6 88 (7.3) 88 (7.3)
M8 220 (18.3) 160 (13.0)
M10 450 (37.5) 325 (27.0)
M12 750 (62.5) 570 (47.0)
M16 1770 (147.5) 1330 (110.0)
M20 3100 (258.3) 2300 (190.0)
M24 5400 (450) . . .
M30 10800 (900) . . .
M36 19000 (1585) . . .
TABLE 5 — Shaft End Threaded Holes – Inches
DRIVE SIZE Input Shaft Output Shaft
03UB .250 x .63 UNF .375 x .75 UNF
04UB .250 x .63 UNF .500 x 1.13 UNF
05UB .250 x .63 UNF .625 x 1.50 UNF
06UB .250 x .63 UNF .625 x 1.50 UNF
07UB .385 x .63 UNF .625 x 1.50 UNF
08UB .375 x .87 UNF .750 x 1.65 UNF
09UB .500 x 1.10 UNF .750 x 1.65 UNF
10UB .625 x 1.42 UNF .750 x 1.65 UNF
12UB .750 x 1.65 UNF 1.00 x 2.17 UNF
TABLE 4 — Tightening Torques – lb-in (Nm) ±5%
DO NOT Lubricate Fasteners
Thread
Dia – UNC
Metal to
Metal
Metal to
Concrete
.250-20 90 (10) 70 (7)
.3125-18 185 (20) 145 (16)
.375-16 330(37) 255 (28)
.500-13 825 (93) 640 (72)
.625-11 1640 (185) 1280 (144)
.750-10 2940 (332) 2290 (258)
– CAUTION –
DO NOT HAMMER
FALK COUPLINGS — (Except fluid type) Detailed installation
manuals are available from Falk, your local Falk
Representative or Distributor; just provide size and type
designations stamped on the coupling. For lubricant
requirements and a list of typical lubricants meeting Falk
specifications, refer to appropriate coupling service manual.
GAP AND ANGULAR ALIGNMENT — If possible, after
mounting coupling hubs, position the driving and driven
equipment so that the distance
between shaft ends is equal to
the coupling gap. Align the
shafts by placing a spacer block,
equal in thickness to required
gap, between hub faces, as
shown, and also at 90° intervals
around the hub. Check with
feelers.
OFFSET ALIGNMENT —
Align driving and driven shafts
so that a straight edge will rest
squarely on both coupling hubs
as shown to the right and also
at 90° intervals. Tighten
foundation bolts of the
connected equipment and
recheck alignment and gap.
SPROCKETS, PULLEYS OR SHEAVES — Mount power
take-offs as close to the gear drive housing as possible to
avoid undue bearing load and shaft deflection.
Align the output shaft of the gear
drive square and parallel with the
driven shaft by placing a
straightedge across the face of the
sprockets or sheaves as illustrated.
Check horizontal shaft alignment by
placing one leg of a square against
the face of the sheave or sprocket
with the spirit level on the
horizontal leg of the square.
DO NOT over tighten belts or chains. Adjust chains to
manufacturer’s specifications. Adjust belts as follows:
The ideal tension is the lowest tension at which the belt will not
slip under peak load conditions. Check the belt tension
frequently during the first 24 to 48 hours of run-in operation.
Over tightening belts shortens belt and bearing life. Keep belts
free from foreign material which may cause slippage. Inspect
the V–belts periodically; tighten the belts if they are slipping.
PINION MOUNTING — Mount pinion as close to the drive
as possible to avoid undue bearing load and shaft deflection.
Refer to the Factory for pinion alignment instructions.
Retaining Methods for Shaft Mounted Drives
The following illustrates methods for retaining shaft mounted
drives.
INSTALLATION AND REMOVAL OF TYPE TA
TAPER®BUSHING
Installation
1. The tapered bore hollow output shaft is designed for use
with a tapered bushing for mounting on a driven shaft
with a straight outside diameter. Refer to Table 6 for
driven shaft tolerances.
2. Rotate driven shaft so that keyway is in the 12 o’clock
position.
THIN WALL BUSHING (with keyway slot through
bushing wall) — With driven shaft keyway at the 12
o’clock position, slide bushing assembly onto driven
shaft, nut end first, and position keyway slot over shaft
keyway (bushing may have to be pried open slightly).
Insert drive key furnished with bushing into shaft keyway.
Proceed to Step 3.
THICK WALL BUSHING (with separate internal and
external keyways) — Insert driven shaft key into driven
shaft keyway. If driven shaft has an open-ended keyway,
stake keyway as illustrated in Figure 9to prevent axial
dislocation of shaft key under operating conditions. Slide
bushing assembly onto driven shaft (bushing may have to
®
The Falk Corporation, P.O. Box 492, Zip 53201-0492288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131November 2002
Installation & Maintenance Instructions •Ultramite ®
(Page 6 of 12) Sizes 03 thru 12 •Type UB
RIGHT WRONG
GEAR DRIVE WALL
LEVEL
SQUARE AND
PARALLEL
STEELFLEX ILLUSTRATED
STEELFLEX ILLUSTRATED
DRIVE RETAINED WITH
PLATE AND FASTENER
DRIVE RETAINED WITH
COLLAR AND SETSCREW
DRIVE RETAINED WITH
RETAINING RING
DRIVE RETAINED WITH
LOCKNUT
DRIVE RETAINED WITH
RECESSED PLATE AND FASTENER
FIGURE 8
TABLE 6 — Driven Shaft Tolerances «
Shaft Diameter — Inches Maximum Undersize — Inches
Up to 1.500 .004
1.500 - 2.500 incl. .005
2.500 - 3.000 incl. .006
HMillimeters = h 10 tolerance.
be pried open slightly). Rotate shaft so that external
keyway in bushing is at the 12 o’clock position. Insert
drive key furnished with bushing into bushing keyway.
Proceed to Step 3.
3. Using a sling, safely lift gear drive so that hollow output
shaft is in the horizontal position. Rotate hollow shaft so
that keyway is aligned with driven shaft/bushing key.
Position and slide drive onto driven shaft taking care that
driven shaft key seats into hollow shaft keyway. DO NOT
hammer or use excessive force.
4. Thread bushing nut onto hollow shaft one to two turns.
Note: The bushing nut threads have been coated with an
anti-seize compound at the Factory. This compound
should not be removed. Before re-installing a previously
used nut, recoat the nut threads (only) with an anti-seize
compound. KEEP TAPERED SURFACE OF BUSHING AND
HOLLOW SHAFT BORE FREE FROM ALL ANTI-SEIZE OR
LUBRICATING COMPOUNDS.
5. Tighten nut as instructed in one of the following methods.
PREFERRED METHOD — Using a spanner (Table 7)
chain or pipe wrench, tighten bushing nut to the torque
value specified in Table 7. Note: For applications where
external vibratory or transient loads may act on drive and
cause setscrews to become loose, apply Loctite 243 or
equivalent to threads of setscrew. Tighten setscrew on
bushing nut.
ALTERNATE METHOD — (Use this method when torque
cannot be measured.) Using a spanner (Table 7), chain
or pipe wrench, tighten bushing nut just until drive can no
longer be moved by hand axially on the driven shaft.
Loosen nut ONLY until it can be turned by hand but do not
unseat the taper. Retighten nut hand tight. Mark a spot on
top of driven shaft. Mark a spot on bushing nut 180° from
the driven shaft mark (90° CCW for Sizes 05UB & 06UB).
Using a spanner wrench, tighten nut CW one half turn until
the two marks are aligned (one quarter turn for Sizes 05UB
& 06UB). Note: For applications where external vibratory
or transient loads may act on drive and cause setscrew to
become loose, apply Loctite 243 or equivalent to threads
of setscrew. Tighten setscrew on bushing nut.
Removal
WARNING: Drive must be supported during removal process.
Use a sling around the gear drive and take up slack before
proceeding.
1. Loosen setscrew on bushing nut located at output end of
hollow shaft.
2. Use aspanner (Table 7) pipe or chain wrench to loosen
bushing nut. Initially, bushing nut will freely rotate counter
clockwise approximately 180° as the nut moves from the
locked position to the removal position. At this point
anticipate resistance which indicates unseating of the
bushing. Continue to turn bushing nut until it is free from
the hollow shaft.
3. Prepare drive for lifting by disconnecting torque arm at
drive end. Slide drive from bushing. Note: Bushing can be
left in place or removed, as required. If bushing will not
slide off of shaft, insert a small pry bar into split of
bushing and pry split open slightly to loosen bushing and
remove from shaft.
SHAFT MOUNTED DRIVES USING A SHRINK DISC
DEVICE
Installation
Shrink discs can be supplied with shaft mounted drives. The
following procedures should be followed when fitting or
removing drives from the driven shaft.
1. Release locking screws gradually and in succession.
Initially a quarter of a turn on each screw will avoid tilting
and jamming – do not remove locking bolts completely.
2. Remove shrink disc from gear drive hollow shaft.
3. Clean and degrease locating diameters of gear drive
hollow shaft, driven shaft and shrink disc locating
diameter on hollow shaft extension.
4. Draw the gear drive onto the driven shaft (See Figure 10).
5. Grease tapered surfaces of outer ring and inner ring with
Molykote 321R or similar.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 November 2002
®
Ultramite ®•Installation & Maintenance Instructions
Type UB •Sizes 03 thru 12 (Page 7 of 12)
CUSTOMER’S SHAFT
LOCKING
SCREW
NOTE: ONLY AVAILABLE AS
STANDARD IN THIS HANDING,
CONTACT FALK FOR OPPOSITE
HANDING.
DRIVEN
MACHINE
SIDE
END
PLATE
FIGURE 10
Table 8 — Tightening Torque – lb-in.
SIZE Locking Screws Torque (lb-in.)
03 257
04 275
05 257
06 257
07 310
08 515
09 515
10 885
12 1415
FIGURE 9
TABLE 7 — Spanner Wrench Type & Spanner
Nut Tightening Torque
DRIVE
SIZE
Adjustable Hook Spanner Wrench Spanner Nut Tightening
Torque lb-ft (Nm)
Armstrong Tools Williams
05UB 34-307 (2.00" - 4.75") 474 83 (113)
06UB 34-307 (2.00" - 4.75") 474 83 (113)
07UB 34-307 (2.00" - 4.75") 474 167 (226)
08UB 34-310 (4.50" - 6.25") 474A 167 (226)
09UB 34-310 (4.50" - 6.25") 474A 250 (339)
10UB 34-310 (4.50" - 6.25") 474A 250 (339)
12UB 34-313 (6.125" - 8.75") 474B 250 (339)
6. Fit shrink disc on gear drive hollow shaft to position
shown on in Figure 10 on Page 7.
7. Tighten all locking screws gradually and in succession.
Do not tighten in a diametrically opposite sequence.
Several passes are required until all screws are tightened.
Ensure that all inner and outer ring faces are in-line and
the torque values show in Table 8on Page 7are
achieved.
8. Fit protective cover.
Note: When the hollow output shaft is to operate in a
vertical position it is essential that the shaft of the driven
machine is provided with a shoulder. When the thrust
load is not taken by the shoulder on the driven shaft, an
end plate, ashown in Figure 10,must be fitted.
It is recommended that customers’ shafts at the
non-clamped end of the sleeve should be coated with
Molykote 321R or equivalent.
Removal
1. Removal procedure is similar to the reverse of installation.
Note: Do not remove shrink disc locking screws
completely.
2. Remove any rust and dirt from gear drive hollow shaft.
3. Withdraw gear drive from driven shaft.
Note: Shrink disc should be removed and cleaned
thoroughly, and Molykote 321R or similar applied to the
tapered surfaces of inner ring and locking collar before
re-use.
Note: Protective covers are supplied with all shrink discs.
Assembly or removal kits and thrust plates are not
provided by the Falk Corporation.
Lubrication Recommendations
Carefully follow lubrication instructions on warning tags and
installation manuals furnished with the gear drive. Nameplates
are stamped with a designation for recommended lubricant;
standard is 6E for triple reduction ratios of 0-45:1, 7E for all
other triple and quintuple ratio drives.
For selection of oil grade based on actual operating
conditions, refer to Table 11, Page9—SeriesUBOilGrades.
Lubricants listed in this manual are typical ONLY and should
not be construed as exclusive recommendations. Refer to your
lubricant supplier for additional lubricants meeting the
indicated specifications. Industrial type extreme pressure (EP)
gear lubricants are the recommended lubricants for ambient
temperatures of 15°F to 125°F (-9°C to +52°C).
For drives operating outside the above temperature range,
refer to “Synthetic Lubricants” paragraphs. Synthetic lubricants
can also be used in normal climates.
VISCOSITY (IMPORTANT) — The proper grades of EP Mineral
and EP synthetic lubricants are found in Table 12, Page 9—
Typical Lubricants. For cold climates refer to “EP Synthetic
Lubricant” paragraphs. Select a lubricant which has a pour point
at least 10°F (5.5°C) below the expected minimum ambient
starting temperature. Usable temperature ranges can sometimes
be widened if specific applications are known.
Extreme Pressure (EP) Mineral Lubricants
Mineral (EP) Lubricants (Table 12) —Industrial type
petroleum based extreme pressure lubricants are preferred.
The EP lubricants currently recommended are of the
sulfur-phosphorus type.
WARNING: EP LUBRICANTS IN FOOD PROCESSING
INDUSTRY — EP lubricants may contain toxic substances and
should not be used in the food processing industry without the
lubricant manufacturer’s approval. Lubricants which meet USDA
“H1" classification are suitable for food processing applications.
Extreme Pressure (EP) Synthetic Lubricants
Synthetic (EP) Lubricants (Table 12) —Polyalphaolefin
type extreme pressure lubricants are recommended for cold
climate operation, high temperature applications, extended
temperature range (all season) operation and/or extended
lubricant change intervals.
WARNING:SYNTHETIC LUBRICANTS IN FOOD
PROCESSING INDUSTRY — Synthetic lubricants may contain
toxic substances and should not be used in the food processing
industry without the lubricant manufacturer’s approval.
Lubricants which meet USDA “H1" classification are suitable for
food processing applications.
®
The Falk Corporation, P.O. Box 492, Zip 53201-0492288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131November 2002
Installation & Maintenance Instructions •Ultramite ®
(Page 8 of 12) Sizes 03 thru 12 •Type UB
Table9—ApproximateOilQuantities – Liters H
Mount-
ing
Position
DRIVE SIZE
Triple Reduction
03UB3 04UB3 05UB3 06UB3 07UB3 08UB3 09UB3 10UB3 12UB3
10.8 1.0 1.5 1.7 3.5 4.5 8.8 14 22
21.0 1.3 1.85 2.8 5.8 8.0 15 24 36
31.0 1.3 1.85 2.8 5.8 8.0 15 24 36
41.3 1.7 2.4 3.3 6.8 9.1 17.5 28.6 41
51.7 2.2 3.1 4.2 8.7 10.4 20.9 33 49
61.0 1.3 1.9 2.9 5.8 9.1 16.3 25.6 35.9
Obtain Quantities for Primary Stage Quintuple Reduction Drives (Separate Oil Sumps)
Mounting
Position
DRIVE SIZE
Quintuple Reduction
03UB5 04UB5 05UB5 06UB5 07UB5
Pri-
mary †
Second-
ary
Pri-
mary †
Second-
ary
Pri-
mary †
Second-
ary
Pri-
mary †
Second-
ary
Pri-
mary †
Second-
ary
201UC2 03UB3 201UC2 04UB3 203UC2 05UB3 203UC2 06UB3 203UC2 07UB3
10.7 0.8 0.7 1.0 0.8 1.5 0.8 1.7 0.8 3.5
20.7 1.0 0.7 1.3 0.8 1.85 0.8 2.8 0.8 5.8
30.7 1.0 0.7 1.3 0.8 1.85 0.8 2.8 0.8 5.8
40.7 1.3 0.7 1.7 0.8 2.4 0.8 3.3 0.8 9.1
51.0 1.7 1.0 2.1 1.4 3.1 1.4 4.2 1.4 10.4
61.1 1.0 1.1 1.3 1.5 1.9 1.5 2.9 1.5 9.1
Mounting
Position
DRIVE SIZE
Quintuple Reduction
08UB5 09UB5 10UB5 12UB5
Primary †Secondary Primary †Secondary Primary †Secondary Primary †Secondary
205UC2 08UB3 205UC2 09UB3 207UC2 10UB3 207UC2 12UB3
11.6 4.5 1.6 8.8 2.8 14.0 2.8 22.0
21.6 9.3 1.6 15.0 2.8 24.0 2.8 36.0
31.6 6.2 1.6 15.0 2.8 24.0 2.8 36.0
41.6 9.1 1.6 17.5 2.8 28.6 2.8 41.0
51.9 10.4 1.9 20.9 3.2 33.0 3.2 49.0
62.5 9.1 2.5 16.3 4.9 25.6 4.9 35.9
HConvert quantities using the following: Liters to US Gallons = Liters x 0.26,
Liters to Imperial Gallons = Liters x 0.22, Liters to US Quarts = Liters x 1.057.
†Primary drives filled with Grade 6E lubricant suitable for all ambient
temperatures between 32°C and 95°F (0°C and 35°C).
The Falk Corporation, P.O. Box 492, Zip 53201-0492 288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 November 2002
®
Ultramite ®•Installation & Maintenance Instructions
Type UB •Sizes 03 thru 12 (Page 9 of 12)
TABLE 10 — Oil Change Intervals Based on
Operating Temperature
Operating
Temperature
Oil Change Intervals
Mineral Oil Synthetic Oil
150°F (66°C) or less 17000 Hours or 3 Years 26000 Hours or 3 Years
158°F (70°C) 12000 Hours or 3 Years 26000 Hours or 3 Years
167°F (75°C) 8500 Hours or 3 Years 21000 Hours or 3 Years
176°F (80°C) 6000 Hours or 2 Years 15000 Hours or 3 Years
185°F (85°C) 4200 Hours or 17 Months 10500 Hours or 3 Years
194°F (90°C) 3000 Hours or 12 Months 7500 Hours or 2-1/2 Years
203°F (95°C) 2100 Hours or 8 Months 6200 Hours or 2 Years
212°F (100°C) 1500 Hours or 6 Months 5200 Hours or 18 Months
TABLE 11 — Series UB Oil Grades
DRIVE
TYPE
Ratio
Range l
Ambient Temperature Range ‡
23°F to 68°F
(-5°C to 20°C)
-22°F to 68°F
(-30°C to 20°C)
32°F to 95°F
(-0°C to 35°C)
68°F to 122°F
(20°C to 50°C)
Triple 0 - 45 5E 5H 6E (5H) 7E (6H)
50 - 160 6E 5H 7E (6H) 8E (7H)
Quintuple All 6E 5H 7E (6H) 8E (7H)
‡Consult Falk representative for other ambient temperatures.
lConsult Falk representative for input speeds below 500 rpm.
TABLE 12 — Typical Lubricants
Recommendations &
Specifications
Mineral Lubricants
Extreme Pressure
AGMA Vixcosity Grade
5EP 6EP 7EP 8EP
ISO Viscosity Grade
220 320 460 680
Nameplate Designation
5E 6E 7E 8E
Ambient Temperature Range °F
Manufacturer Lubricant +23 to
+77
+32 to
+104
+50 to
+122
+68 to
+122
Chevron USA, Inc. Gear Compound EP 220 320 460 680
Exxon Co. USA Spartan EP 220 320 460 680
Mobil Oil Corp. Mobilgear 630 632 634 . . .
Shell Oil Co. Omala Oil 220 320 460 680
Synthetic Lubricants ‡
Extreme Pressure (Except
where noted) †
AGMA Viscosity Grade
5S 6S 7S 8S
ISO Viscosity Grade
220 320 460 680
Nameplate Designation
5H 6H 7H 8H
Ambient Temperature Range °F
Manufacturer Lubricant +14 to
+86
+32 to
+113
+50 to
+122
+68 to
+122
Conoco Inc. SynconR&O 220 ... 460 ...
Exxon Co. USA Teresstic SHP
Spartan Synthetic EP SHC
220
220
320
320
460
460
680
680
Mobil Oil Corp. Mobil SHC
Mobilgear SHC
630
220
632
320
634
460
636
680
Pennzoil Products Co. Pennzgear SHD
Super Maxol “S”
220
220
320
320
460
460
680
...
†Consult lubricant supplier/manufacturer for maximum operating temperature.
‡Lubricant does not contain EP (extreme pressure) additives. Consult your
lubricant supplier for additional lubricant recommendations.
Oil Levels
Drives Sizes 03-07 are furnished filled with oil determined by
the Drive Mounting Position. Refer to Table 12 for alist of
typical lubricants meeting Falk specifications. Refer to Table 9
for appropriate quantities of oil based on mounting position
shown below.
MOUNTING (CAUTION) — Mount drive unit only in the
position for which it was ordered. See below for the placement
of the vent, drain and oil level plugs based on drive size and
mounting position. If it is necessary to mount the drive in a
special orientation not shown below, including rotated and
tilted drives, consult the Falk Corporation for changes
necessary to provide proper lubrication. Refer to Table 9for
approximate quantities of oil by the drive mounting position.
®
The Falk Corporation, P.O. Box 492, Zip 53201-0492288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131November 2002
Installation & Maintenance Instructions •Ultramite ®
(Page 10 of 12) Sizes 03 thru 12 •Type UB
SYMBOL KEY
AIR VENT
OIL FILL
OIL LEVEL
OIL DRAIN
MOUNTING 1
MOUNTING 3
MOUNTING 5
MOUNTING 2
MOUNTING 4
MOUNTING 6
Lubricant Changes
All drive sizes require regular oil changes as instructed in this
manual.
OIL ANALYSIS REPORT — Checking oil condition at regular
intervals is recommended. In the absence of more specific
limits,
The guidelines listed below may be used to indicate when to
change oil:
1. Water content is greater than 0.05% (500 ppm).
2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm.
4. Viscosity changes more than 15%.
5. Oil temperature; drive operating under load.
6. Lubricant type.
7. Operating conditions; shock, loading, etc.
8. Mineral oil content exceeds 10% of oil fill quantity.
The effective life of an oil is greatly reduced at elevated
temperatures. This is most pronounced with oils containing
fatty and EP additives. To prevent damage to the drive through
lubricant breakdown, the oil should be changed at the
intervals shown in Table 10 —Oil Change Intervals. Intervals
shown are for oil temperatures when the drive has attained
normal running temperature when operating under load.
These intervals are based on normal running. Where
conditions are particularly severe, it may be necessary to
change the oil more frequently. When changing oil, if the
same oil is not used, flush drive and fill with only one type of
oil.
The initial oil should be changed in a new gear drive after
1000 hours of operation or one year or half the above life,
whichever occurs first.
Preventive Maintenance
AFTER FIRST WEEK — Check alignment of the total system
and realign where necessary. Also, tighten all external bolts
and plugs where necessary.
DO NOT readjust the internal gear or bearing settings in the
drive, these were permanently set Falk.
PERIODICALLY — Carefully check the oil level of the drive
when it is stopped and at ambient temperature, add oil if
needed. If the oil level is ABOVE the oil level plug, have the
oil analyzed for water content. If moisture content exceeds
500 ppm, change the oil. DO NOT fill above the oil level
plug as leakage or undue heating may result. Grease drives
with grease lubricated bearings monthly; refer to Table 13 —
Typical Greases Recommendations & Specifications. Check
coupling alignment to make certain that foundation settling
has not caused excessive misalignment.
Bearing Greases
Some Ultramite gear drives have one or more grease
lubricated bearings. Whenever changing oil in the drive,
grease the bearings with one of the greases listed in Table 13
— Typical Grease Recommendations & Specifications.
Regrease these bearings as part of the standard maintenance
program. Before installing a drive, note the location of all of
the bearing grease fittings and grease labels for future
maintenance reference. Note that some fittings may be above
the oil level line and others below. If a grease fitting will
become inaccessible after drive is installed, replace the fitting
with a pipe extension (and the fitting) so that the grease fitting
will be in an accessible location after the drive is installed.
Always remove the purge plug (when provided) when greasing
bearings so that the old grease can escape. Wipe off purged
grease and replace the plug after greasing bearings.
Some of the greases listed in Table 13 may contain toxic
substances and should not be used in the food processing
industry without the grease manufacturer’s approval. A grease
that meets the USDA “H1” classification is suitable for food
processing applications.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 November 2002
®
Ultramite ®•Installation & Maintenance Instructions
Type UB •Sizes 03 thru 12 (Page 11 of 12)
TABLE 13 — Typical Grease Recommendations
& Specifications
Manufacturer Grease H†
Allowable Operating Temperature
Range
Above To
Applied Chemicals LTD 4020-220-2 32°F (0°C) 248°F (120°C)
BP Oil LTD LS EP2 -22°F (-30°C) 266°F (130°C)
Century Oils LTD Lupus A3 -22°F (-30°C) 257°F (125°C)
Esso Petroleum Co. LTD/Exxon Beacon EP2 -13°F (-25°C) 257°F (125°C)
Chevron Gulf Oil (GB) LTD Crown EP -22°F (-30°C) 248°F (120°C)
Kluber Lubrication Centoplex 2 -4°F (-20°C) 266°F (130°C)
Koolex International Q8 Rembrandt EP2 -22°F (-30°C) 248°F (-120°C)
Lubrication Engineering Almaplex 1275 -22°F (-30°C) 320°F (-160°C)
Mobil Oil Co. LTD Mobilux EP2 -4 (-20°C) 266°F (130°C)
Shell Oils Albida R2 -4 (-20°C) 302°F (150°C)
Texaco LTD Multifax EP2 32°F (0°C) 248°F (120°C)
HGreases are suitable for use with lubricant oil Types M, A and H. Type G
lubricant is also suitable, however, the oil must be changed when the amount
of grease re-lubrication exceeds 10% of the drive’s oil fill quantity.
†Consult Falk Application Engineering Department if:
1. Drive has grease lubricated bearings and Type G oil is to be used.
2. Drive operates in ambient temperatures outside of range -22°F to 122°F
(-30°C to 50°C).
Stored & Inactive Gear Drives
Each gear drive is protected with rust preventive that will protect
parts against rust for a period of 6 months in an indoor dry
shelter.
If a gear drive is to be stored, or is inactive after installation
beyond the above periods, drain oil from housing and spray
all internal parts with a rust preventive oil that is soluble in
lubricating oil or add “Motorstor™” vapor phase rust inhibitor
at the rate of one ounce per cubic foot of internal drive space
(or 5% of sump capacity) and rotate the shafts several times by
hand. Before operating, drives which have been stored or
inactive must be filled to the proper level with oil meeting the
specifications given in this manual. Refer to Manual 128-014
for “Start-up after Storage” instructions.
Periodically inspect stored or inactive gear drives and spray or
add rust inhibitor every six months, or more often if necessary.
Indoor dry storage is recommended.
Gear drives ordered for extended storage can be treated at
Falk with a special preservative and sealed to rust-proof parts
for periods longer than those cited previously.
Material Safety Data
For material safety data sheets pertaining to products used in
the manufacture of the Falk Ultramite, contact:
The Falk Corporation
Customer Service Department
3001 W. Canal Street
Milwaukee, WI 53208-4200
Phone: (414) 342-3131
®
The Falk Corporation, P.O. Box 492, Zip 53201-0492288-400
3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131November 2002
Installation & Maintenance Instructions •Ultramite ®
(Page 12 of 12) Sizes 03 thru 12 •Type UB
Table of contents
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